Supplier Training: Fastener Torque

Supplier Training: Fastener Torque Presenter: Ralph White Senior Fastener Specialist, Chrysler Group LLC Main Topics: Common definitions uses within Chrysler and Fiat Documentation and communication methods Assembly plant fastener related controls to aid process capability 1

General Overview of Torque Torque is the twisting (turning) force applied to a nut, which generates tension in the bolt and results in clamping force on the parts. Torque = Force x Length 2

Torque definitions within Chrysler and Fiat Torque Equation: The applied torque and resulting bolt tension are most often modeled as a linear function for the purpose of design. The equation is as follows: T = kdf Where k = the friction factor (dimensionless) D = the bolt nominal diameter (in., m) F = the clamp load tension force (lb., N) T = the torque (in.-lb., Nm) Average k factors for various Chrysler Group fastener finishes are developed experimentally and can be determined by using the certification M10 screw and conical washer assemblies torque requirement found in our coatings specifications. Please be aware that some finishes have a large amount of variation so these values are intended to provide an approximation to aid fastener selection. COMMON TERMINOLOGY Chrysler Fiat Dynamic Torque Imposed Torque Tightening Torque Residual Torque Control Torque Inspection Torque Snug Torque Angle control initial Torque Torque Control with Angle Monitor Monitored Angle Imposed Angle with Torque Control CoDeP - This is the proper spelling and casing. CoDeP stands for Configuration and Description of Product CoDeP is Fiat s EBOM equivalent Angle Control with Torque Monitor Monitored Dynamic Imposed Torque with Angle Control Expected Clamp Load Traction 3

PS-809 Torque Tightness Inch Threaded Parts Torque definitions Power tool torque methods Torque inspection methods Min. length of thread engagements for tapped holes Stud seating torque, etc. 4

Dynamic Torque (Fiat: Imposed & Tightening Torque) Dynamic Torque is the torque measured by an electronic torque transducer contained within, or attached to, the tooling during the tightening process. Dynamic torque is inherently more repeatable and more closely related to controlling clamp load which affects the quality of the joint build. Unless specified, dynamic torque can vary from plant to plant that builds the same joint because of the tool type, speed, etc. Currently, this field is empty on many applications which allow manufacturing flexibility in tool selection. However, future releases will require more dynamic torque specifications to aid power tool commonization. Where is Dynamic torque required? On all joints assembled at our plants. Where to find Dynamic torque values and normal torque tolerances? Preliminary dynamic torque specification can be found in PS-6239. Carry over from other releases. Fastener Engineering experimentally develops the torque specification for all joints based on dynamic failure torque to optimize joint clamp load. 5

Residual Torque (Fiat: Control & Inspection Torque) Residual Torque is the torque required to slightly restart, in the tightening direction, a previously tightened torqueable component immediately after the fastening operation is completed. It is the value obtained when the secured fastener begins to rotate when measures by a mechanical or electronic hand torque wrench. The residual torque variation is always greater than dynamic torque variation due to joint relaxation, torque decay, friction and operator technique. Why is residual torque needed? Residual torque is a process to verify that the joint was tightened and an indicator for part or process variations that may affect the joint clamp load. Common denominator for one vehicle built at multiple plants, joint inspection (PG, safety, etc.). Where to find residual torque values and normal torque tolerances? Preliminary residual torque specification values can be found in PS-6239. Carry over from other releases. Developed in the Fastener lab, pilot build and/or the assembly plant. 6

Determining Dynamic Tolerance Range using Tightening Class for Metric Fasteners TABLE 1: DYNAMIC TORQUE TIGHTENING CLASS TOLERANCE RANGES Tightening Class Dynamic Torque Tolerance (1) A + 5 % B + 10 % C + 20 % D + 30 % NOTE 1: Below is a brief explanation of Tightening Class A, B, C and D, with corresponding Dynamic Torque Tolerance range based on joint types: A. Used on clamp load sensitive and critical joints requiring a DC electric power tool using the Standard Torque, Torque Control with Angle Monitoring, Angle Control with Torque Monitoring, and unique Yield Control strategies. The Snug torque is mandatory for strategies other than Standard Torque and requires Fastener Engineering review with possible development for Tightening Class A. Examples are hard joints like internal engine (cylinder head and connecting rod bolts), powertrain gears, and tapered ball joint applications. B. Used on clamp load sensitive and critical joints assembled with a DC electric tool with Standard Torque and Torque Control with Angle Monitoring strategies. The Snug torque is mandatory for Torque Control with Angle Monitoring and Angle Control with Torque Monitoring strategies and requires Fastener Engineering review with possible development for Tightening Class B. Examples are hard and medium joints like electrical high current, chassis (steering gear and wheel lug nuts), brake systems, external engine and powertrain adaptation joint applications. C. Used on joints with DC electric and pneumatic tools at assembly for the Standard Torque strategy. Examples are medium and soft joints exhaust hanger bracket attachments, heat shields, non-safety module attachment and hose/tube routing types of joint applications. D. Used on non critical joints assembled using pneumatic and battery powered tools at assembly for the Standard Torque strategy. Examples are soft joints involving plastic in the joint and tapping screw attachments. At Chrysler, Class D is not recommended without Fastener Engineering review. Using this class for standard machine threaded nuts and bolts should be avoided because the high torque range could result in the bolt breaking. 7

PS-6239 Torque Tightness Metric Threaded Parts Fastener Size (7) Target Torque FGA 01391 Property Class 8.8 and 10.9 TABLE 2: ESTIMATED DYNAMIC & RESIDUAL TORQUE (FGA / Chrysler) (9) Target Torque (Nm) Chrysler Loose Washer Ass'y (3, 6, 8) Property Class 8.8 / 10.9 Target Torque (Nm) Chrysler Flange (4, 6, 8) Property Class 8.8 / 10.9 Residual Torque Range Newton (Nm) Dynamic Torque Range (Nm) Expected Clamp Expected Clamp Load Load (5) at Target N at Target Torque Torque FGA 01391 Chrysler Property Class 8.8 / 10.9 M 5 x 0.8 See Note (2) 5 / 8 6 / 9 FGA See norm See Dynamic See Note (2) 6581 / 9417 M 6 x 1.0 See Note (2) 9 / 13 11 / 15 01393/01, Chrysler Torque Tightening See Note (2) 9338 / 13362 M 8 x 1.25 See Note (2) 22 / 31 25 / 37 see Table 3 Class Tolerance See Note (2) 16986 / 24308 M 10 x 1.25 (1) See Note (2) 45 / 65 54 / 77 Ranges different from Ranges See Note (2) 28396 / 40636 01393/01 must be Table 1 M 10 x 1.5 See Note (2) 43 / 62 51 / 73 reviewed by See Note (2) 26907 / 38505 M 12 x 1.25 (1) See Note (2) 82 / 115 97 / 135 Fasteners See Note (2) 42722 / 61136 M 12 x 1.5 (1) ---- 79 / 110 93 / 130 Engineering and Manufacturing ---- 40890 / 58516 M 12 x 1.75 See Note (2) 75 / 105 89 / 125 See Note (2) 39100 / 55953 M 14 x 1.5 (1) See Note (2) 125 / 185 150 / 220 See Note (2) 57789 / 82698 M 14 x 2.0 See Note (2) 120 / 170 140 / 200 See Note (2) 53564 / 76652 M 16 x 2.0 ---- Contact Fastener Engineering ---- 72694 /104028 M 16 x 1.5 (1) ---- Contact Fastener Engineering ---- 77603 /111053 NOTE 1: Indicates a fine thread pitch NOTE 2: For FGA vehicles, the target dynamic torque and expected clamp load are in Fiat Norm 01391 section 1.1 table. NOTE 3: Chrysler target torque values (i.e. nominal torque (Cnom)) for Screws and Nuts with captured loose conical washer based on strength class. NOTE 4: Chrysler target torque values (i.e. nominal torque (Cnom)) for Screws and Nuts with flanged bearing surfaces based on strength class. NOTE 5: Within Fiat Norm 01391 the word Traction is the same as Expected Clamp Load. NOTE 6: Grade 9.8 was omitted and grade 8.8 should be used as a default. NOTE 7: Contact Fastener Engineering for sizes not shown. NOTE 8: Chrysler torque values are based on a K-factor of 0.16 for loose washer assemblies and 0.19 for flange fasteners. The clamp force is 80% proof load for 8.8 and 10.9 strength level property classes. Using the equation: Torque = Nominal bolt diameter x K-factor x force. Example M8 x 1.25 washer assembly: torque = (8mm x 0.16 x 16986 N) / 1000, (Hint: Watch the units of measurement 10-3 mm = 1m), therefore torque = 21.7 Nm or 22 Nm. Some dynamic torque values have been rounded down to values found in Table 3. NOTE 9: See Table 4 to compare Fiat and Chrysler torque terminology. 8

NOMINAL DYNAMIC TORQUE & CORRESPONDING RESIDUAL TORQUE VALUES Nominal Allowed limits, upper (V MAX,A ) and lower (V min,a ) limits for the value of C A (Nm) Torque(3) Class A Class B Class C Class D (Nm) V min,a V MAX,A V min,a V MAX,A V min,a V MAX,A V min,a V MAX,A 1 1 1.3 0.9 1.3 0.7 1.4 0.6 1.4 1.5 1.5 1.9 1.4 2 1.1 2 0.8 2.1 2 1.9 2.6 1.8 2.7 1.4 2.7 1.1 2.8 2.5 2.4 3.2 2.3 3.3 1.8 3.4 1.4 3.5 3 2.9 3.9 2.7 4 2.2 4.1 1.7 4.2 3.5 3.4 4.5 3.2 4.6 2.5 4.8 1.9 4.9 4 3.9 5.2 3.7 5.3 2.9 5.5 2.2 5.6 4.5 4.4 5.8 4.1 6 3.2 6.1 2.5 6.3 5 4.8 6.5 4.6 6.6 3.6 6.8 2.8 7 5.5 5.3 7.1 5 7.3 3.9 7.5 3.1 7.7 6 5.8 7.8 5.5 8 4.3 8.2 3.3 8.4 21 20 27 19 28 15 29 12 29 22 21 29 20 29 16 30 12 31 23 22 30 21 31 17 31 13 32 24 23 31 22 32 17 33 13 34 25 24 32 23 33 18 34 14 35 TABLE 3 NOTES: NOTE 1: Residual Torque values are found in Fiat norm 01393/01 Table A. When not specified on drawings or EBOM, the joint is intended to be a Class B. Pages from publication dated 05/11/2001 are attached for your reference and noted as Table 3. NOTE 2: Table A is based on a statistical combination of standard settings and measurement errors to determine Vmin, A and VMAX, A calculated as outlined in Fiat 01393/01. The minimum Residual Torque (Vmin, A) and maximum Residual Torque (VMAX, A) are for a given Nominal Torque (Cnom) from table 2. At Chrysler, the Nominal Torque (Cnom) is the same as CA defined in Fiat 0.00010/01. NOTE 3: When the exact Nominal Torque value is not found in Table 3, round up or down to the next significant value. Examples are 153 Nm would round up to 155 Nm and 152 Nm would round down to 150 Nm. The Nominal Torque is also considered the target Residual Torque value. For Nominal Torque values less than 1 Nm and greater than 275 Nm contact Fastener Engineering. 9

Snug Torque (Fiat: Angle control initial torque) Snug Torque is a torque level that triggers a programmed event in the tooling, such as angle encoders, tool speed adjustments, tool synchronization, etc. The torque that produces a little clamp load to pull the joint members together, flattens conical washers, surface discontinuities, etc. and establishes a predictable torque vs. angle relationship. Not all joints are capable of having a predictable snug torque (i.e.. Soft joints). Where is Snug torque required? Angle control w/torque monitor or torque control w/angle monitor tightening strategies. Where to find a Snug torque value? They are determined experimentally. 10

Finding a Dynamic Torque Value Standard Machine Threaded Fasteners 11

Finding a Dynamic Torque Value Tapping Screw Dynamic Torque Graph Torque to Strip Strip Torque must be 4 x the tapping torque. Dynamic Torque Spec. 0.025 inch thick CRS sheet metal PCI Torque to Tap Transition Stage 12

Special Torque Tightening Strategies Torque Control w/angle Monitoring (Fiat: Monitored Angle) This is a strategy that can provide detection of joint defects such as cross threading, out of flatness, soft bolts, stripped threads, etc. Where is it needed? Chassis and Powertrain applications like control arms and steering gears. Where to find the angle and torque values? They are determined experimentally. Angle Control w/torque Monitoring (Fiat: Monitored Dynamic) Angle Control with Torque Monitoring is often used if torque control fastening strategy does not result in acceptable joint clamp load. This strategy reduces the influence of friction as a variable in achieving a desired clamp load, commonly called turn-of-the-nut. This is a strategy that can provide detection of joint defects such as cross threading, out of flatness, soft bolts, stripped threads, etc. Where is it needed? Unique applications like tapered ball joints and connecting rods. Where to find the angle and torque values? They are determined experimentally. 13

Safety Shield & Critical Applications Chrysler Designations Safety shielded torque is identified as Critical application torque is identified as on the torque AMPS sheet. on the torque AMPS sheet. Fiat Designations Safety shielded torque is identified as D on the Fiat vehicle specific torque standard and is equal to Chrysler Safety identification. Critical application torque is identified as R on the Fiat vehicle specific torque standard and is equal to Chrysler Diamond identification. 14

Minimum Audit Torque (Fiat: Does not use min. audit) Minimum Audit Torque is the torque applied in the tightening direction by a hand torque wrench on an installed torqueable component. The audit torque minimum must be achieved without the torqueable component rotating. Audit torque values should allow for any in plant torque loss without regard to length of time since tightening. The exception is when Min. Audit replaces residual torque as an inspection method for special joints. Then min audit has to be conducted in the same amount of time as the residual torque inspection. Where is Audit needed? On a joint that is subject to relaxation after assembly and special joints as an inspection method to replace Residual Torque inspection. Where to find the Audit torque values? They are determined experimentally to monitor joint relaxation. Carry over from other releases. Developed in the Fastener lab, pilot build and/or the assembly plant. 15

Chrysler Current Process for EBOM-AMPS BOM Analyst Part Number, Assembly Structure, and Usage changes WebCN CN used to enter Torque data and enotes to feed EBOM tables Systems & Components Engineering EBOM AMPS receives CN activity and Torque data via system interfaces and ME Process apply it to process sheets AMPS ME Process Assembly Plants utilizes AMPS Process sheets to obtain Torque data Assembly Plant 16

Torque WebCN 17

Typical EBOM Torque Screen 18

Manufacturing AMPS Process Sheet with Torque 19

Equal to Fiat Inspection or Control Torque. All applications require a value input here. Dynamic value inputs here from Tightening Torque in Fiat std.. Will Use standard Tolerance classes in future. Snug Torque is equal to the same as Fiat. Monitored Dynamic is equal to the same as Fiat standards. Torque control with angle monitoring has no equivalent in the Fiat standards. (Codep will have this) Angle value is same as Fiat. Any tolerance can be used 20

This is the Snug torque plus angle specifica9on. Tightening class tolerances per Fiat std 01390/01 These are know as Monitored Dynamic torque. Only to be used in angle control applications Method A is understood as Residual torque. Except as noted per instruc9ons. This check according to Fiat specs allows up to 2 hours to be completed. Angle tolerance for specifications above. 21

This is the Snug torque. Tightening class tolerances per Fiat std 01390/01 These are know as Monitored Dynamic torque. Only to be used in angle control applications. Angle tolerance This is understood as Residual torque. Method A means to check ader the Dynamic has been applied. 22

These applications do not have any Residual torque specified. This is understood as Residual torque. No9ce for some applica9ons such as tapping screws, there is no Residual torque check. In these cases, use the Dynamic Target from Tightening torque column and apply +/- 30% and input to the Residual field in EBOM. This will be a temporary measure. 23

On behalf of myself and Chrysler Group LLC, we appreciate the opportunity to share some fastener torque definitions and processes. Are there any questions? 24